Cogen Heat Recovery Boiler Three Element Feed Water Control

1.0 Introduction
This technical report describes how a cogeneration power plant functions. Component
sizing as well as an appropriate control system for the heat recovery boiler is determined
in this report. Several control loops are used to properly control the heat recovery boiler.
Three element feed water control combines a level loop and two flow loops to properly
maintain the water level inside the boiler. Continuous boiler blowdown has also been
used to maintain boiler efficiency. Proper pump sizing pipe sizing as well as orifice plate
sizing are calculated throughout the sections of this report. Certain loops that I have
selected are also animated using the P!C"# which is available in our lab.
This report has been written to meet the re$uirements of the third year %utomation
Technology course. Cogeneration power plants are an environmentally friendly method
of producing power& this is because they produce two types of energy. 'eat and power
using only one fuel source are produced. The heat produced can then be turned into
steam which powers a second turbine and produces additional power. (asically a
cogeneration plant ta)es wasted energy and turns it into usable power.
*y report contains a full P+I diagram wiring diagrams P!C programming component
selection and sizing for valves pipes as well as orifice plates. I have also documented the
1
separate loops which automate my system. Several drawings are also found throughout
my technical report to illustrate certain parts of the process.
,.0 Cogen Power -eneration
,.1 .efiniton
Cogeneration power plants are power generating facilities that produce both heat and
electricity using a single fuel such as natural gas. 'eat produced from the production of
electricity such as the firing of a gas turbine is recycled and used to produce steam. This
additional steam can be used for additional plant processes for domestic purposes or to
power a second turbine which produces additional electricity.
,., (enefits
The benefits of cogen are numerous. Single purpose thermal electric power plants re/ect
between #00 and 1#0 of the fuel heat to rivers la)es the ocean or the atmosphere.
Cogeneration systems use this re/ected heat into a usable power source. (y using wasted
heat and turning it into a usable source of energy the cogen power plants can increase
their efficiency This added efficiency is e2tremely desirable nowadays because of the
ever 3 increasing price of fuel as well as the growing concerns for our environment.
%nother benefit of cogeneration type power plants is the lac) of line losses& this is
,
because power is generated on site and the need to run additional power lines is non"
e2istent.
,.4 Se$uence of 5peration
(asically all cogen power plants have some form of primary fuel that is burned 6this can
be fuel natural gas coal ect.7. The primary fuel is burned which creates a lot of heat and
pressure this heat and pressure is then used to spin a turbine which in turn spins a
generator. Power is then produced from the generator. %ll the while the primary
combustion is occurring the cogen power plant uses as waste heat boiler. The hot
e2haust gases left over from the primary combustion process are sent through heat
e2changers which heat up steam in a boiler. It is only after that most of the heat energy
is removed from the hot e2haust gasses is it sent up the stac) and released to atmosphere.
The additional steam produced by the heat recovery boiler is then used to power a steam
turbine which powers a second generator. %dditional power is generated from the
second generator ma)ing the cogen power plants more efficient. 8or a visual on how the
system actually wor)s refer to 8igure ,.4.1.
4
Figure 2.3.1 Cogen Overvie !htt"#$$.cogen.org$cogen%challenge$&u""ort$image&.htm'
4.0 'eat 9ecovery (oiler Control
The overall P+ I drawing for my control system can be found in the following section.
:ou will also find 4 element feedwater boiler blowdown and basic boiler safety in the
following section of this report.
4.1 Process and Instrumentation .iagram
The overall process and instrumentation diagram for the boiler control system is pictured
in figure 4.1.1.
;
Figure 3.1.1 Overall ( ) * +iagram
#
4., Three <lement 8eed =ater Control
Three element feed water control has been selected in this case. The water level inside
the boiler is critical. If boiler level is too low the heating tubes will be e2posed which
will damage them. Too high a level will interfere with steam separation. (oth cases can
prove disastrous. In a three element system input flow output flow as well as level are
measured. *easuring and controlling three elements will ensure tight boiler level
control. 8igure 4.4.1 shows three element feed water control. :ou can see the outlet
steam flow feed water flow as well as boiler drum level are all monitored.
Figure 3.2.1 Three Element Feed Water
4.4 Continuous (oiler (lowdown
(oiler feedwater even after having been treated will contain impurities and minerals. If
these minerals aren>t removed from the boiler scaling and corrosion will occur on it>s
inside surfaces. This buildup can be avoided with proper boiler blowdown. (lowdown
1
will occur in , areas of the boiler drum. The first blowdown line will lead up to the top
watermar) in the boiler when this valve is opened all froth will be evacuated from the
drum. The second blowdown line will be installed into the bottom mud drum where all
the heavier solids will accumulate. Continuous boiler blowdown will be used in this
case& this signifies that a set ratio of blowdown will occur in proportion to the input of
feedwater flow. % set ratio of 100?1 will suffice for continuous blowdown versus inlet
flow.
4.; (asic (oiler Safety
%s was e2plained in an %<T: in class handout because of the energy in boilers safety
during start"up shutdown and normal operation is very important. Safety is a go @ no go
situation. If safety limits are e2ceeded 5A@588 controls disable the operation of the
boiler.
(elow you will find the basic safety interloc)s?
Purge interloc) "prevents fuel from being admitted to an unfired furnace until the
furnace is thoroughly purged with air
!ow air flow "fuel is shut off upon loss of air flow
!ow fuel supply "fuel is shut upon loss of fuel supply
!oss of flame "all fuel is shut off upon loss of flame in furnace and or to an
individual burner
B
8an Interloc) "stop forced draft upon loss of induced draft fan
!ow water "shut off fuel on low water level in boiler
.amper interloc) "shut dampers if fans are not operating
;.0 P!C # Programming
%llen (radley>s P!C # as well as 9oc)well %utomation>s 9Slogi2 P!C programming
software is used for automating the system.
;.1 P!C Information
The following table lists all cards installed into the P!C rac)?
Ta,le -.1.1 (.C *n/ormation
Processor Type : Allen Bradley PLC-5/40C - 16 slot rack
Rack # Slot # escr!pt!on Part #
00 C0 Ethernet Adapter Card
00 C1 AC Input Module 1771-IA2
00 C2 Analog Input Module 1771-IFE/C
00 C3 Analog Output Module 1771-OFE/B
00 C4 Empty
00 C Empty
00 C! Empty
00 C7 Empty
01 C" Empty
01 C# Empty
01 C10 Empty
01 C11 Empty
01 C12 Empty
01 C13 Empty
01 C14 Empty
01 C1 Empty
C
;., Symbol Table
The following table lists all the I@5 addresses as well as descriptions.
Ta,le -.2.1 (.C 0ym,ol Ta,le
Address "a#e Type escr!pt!on
I$001/0 %A%% &I %e'el Alarm ()gh - ()gh
I$001/1 %A%% &I %e'el Alarm ()gh
I$001/2 %A( &I %e'el Alarm %o*
I$001/3 %A(( &I %e'el Alarm %o* - %o*
+10$ C,1 AO Bo)ler Feed -ater ,al'e
+10$! C,2 AO Bo)ler Blo*do*n ,al'e
+10$7 C,3 AO Bo)ler Blo*do*n ,al'e
+10$22 F.1 AI /team Output Flo* .ran0m)tter
+10$23 F.2 AI Bo)ler Blo*do*n Flo* .ran0m)tter
+10$24 F.3 AI Bo)ler Blo*do*n Flo* .ran0m)tter
+10$2 F.4 AI
Bo)ler Feed -ater Flo*
.ran0m)tter
+10$2! %. AI Bo)ler %e'el .ran0m)tter
;.4 Aetwor) .escriptions
The complete P!C ladder logic programming as well as individual networ) descriptions
is found in %ppendi2 % 3 DP!C ProgramE at the end of this report.
F
#.0 9Sview
9oc)well %utomation>s 9Sview software is used to create a -GI 6-raphical Gser
Interface7. 8igures #.0.1 shows a screen capture of the completed -GI.
Figure 1.2.1 R03ie 0creen Ca"ture
1.0 =iring .iagrams
1.1 (oiler !evel Switch =iring?
In figure 1.1.1 you can see both level alarms which each contain two probes& they are
wired into the %C input module in slot C1 of the P!C #.
10
Figure 4.1.1 .evel 0itch Wiring +iagram
1., !evel and 8low Sensing <lements?
8igure 1.,.1 shows the wiring for all flow and level transmitters. They all happen to be
9osemount 11#1 differential pressure transmitters.
11
Figure 4.2.1 Tran&mitter Wiring +iagram
1,
B.0 Pump Calculations
B.1 Pump Sizing
5' 0tatic 0uction .i/t H #0> of li$uid I B00 psia H ",0#F.F,;>
B' 0uction 0ide .o&&e& H
Pipe Size? #E sch ;0
Ta,le 6.1.1 (um" *nlet Fitting& .o&&e&
P$#p %nlet & '!tt!n(s Losses
Component 1 Ft E2u)'3 lenth 4uant)ty
Entry 037" 20 1
E5)t 1 2 1
El6o* 7#089 30 14 1
: 0;h 40 ! 1
.otal E2u)'alent <)pe %ength$ 124=
.P !e H 1.B0 psi H #.004>
C' Total +ynamic 0uction .i/t H ",0#;.F,1>
+' 0tatic +i&charge Head H 10>
E' +i&charge 0ide .o&&e& H
Pipe Size? #E sch ;0
14
Ta,le 6.1.2 (um" +i&charge Fitting& .o&&e&
P$#p !sc)ar(e & '!tt!n(s Losses
F)tt)ng 1 Ft E2u)'alent %ength 4uant)ty
Entry 037" 20 1
E5)t 1 2 1
El6o* 7#089 30 14 2
: 0;h 40 10 1
.otal E2u)'alent <)pe %ength$ 223=

.P !e H 4.01 psi H F.00#>
F' Total +ynamic +i&charge Head H 1F.00#
7' Total +ynamic 0uction .i/t H ",0#;.F,1
H' Total +i&charge Head 8 912 "&ia H ,BF#.#1>
T+H H B10.#1#>
B., Calculating pump motor horsepower
=ater 'orsepower? 6JKT.'KS.-.7 @ 4F10
H B#.41# 'P
(ra)e 'orsepower? H14B.0,B 'P
B.4 Pump Specifications
1;
8igure B.4.1 is the pump curve for the selected pump. Aote that I have made a mar) on
the drawing where #00 -P* and B10 T'. meet so that I may gather the rest of the
information that is re$uired to purchase a correct pump.
Figure 6.3.1 7ould (um" Curve !5ET: in cla&& handout'
'ere is a list of the specifications needed for this application?
1#
;a<e# -ould
;odel# 4B00
0i=e# 4L;"11
*m"eller 0i=e# 1;E
0"eed# 4##0 9P*
Hor&e"oer# 14B.0,B
E//iciency# ##0
C.0 Malve sizing
There are 4 control valves in the overall P+I drawing. :ou will find the specifications as
well as size calculations for these valves in the following section.
C.1 8eedwater valve sizing
11
Cv H J s$r. 9oot 6-f @ .p7
> H #00 gpm
7/ H 0.BC;C
+" H 10 psi
0olution H Cv H 1;0.0B
C., (lowdown valves sizing
Cv H J s$r. 9oot 6-f @ .p7
> H ,.#
7/ H 0.BC;C
+" H 10 psi
0olution H Cv H 0.B00
C.4 Malve Selection
1B
8or complete valve selection order code brea)down see appendi2 ( entitled DControl
Malve SelectionE at the bac) of this report. Table C.4.1 contains re$uired valve
specifications.
Ta,le ?.3.1 3alve &"eci/ication&
F.0 Pipe sizing
1C
In the following section the size or various pipes is calculated losses through the fittings
are also ta)en into account.
F.1 Pump discharge to boiler pipe
Figure 9.1.1 (um" +i&charge to Boiler (i"ing +iagram
Ta,le 9.1.2 .o&&e& through Fitting&
1F
P$#p !sc)ar(e to Bo!ler P!pe & '!tt!n(s Losses
F)tt)ng 1 Ft E2u)'alent %ength 4uant)ty
Entry 037" 20 1
E5)t 1 2 1
El6o* 7#089 30 14 2
: 0;h 40 10 1
.otal E2u)'alent <)pe %ength$ 223=
'ere are the re$uired formulas to size the pipe as found in the Crane manual?
+( H 0.000,11 6f!pJN,7 @ dN# 6Crane 4",7
/ H I will use a friction factor of 0.011 6Crane %",17 to begin my calculation
. H ,,4 feet
" H ;C.F;C 6Specific gravity of boiler feedwater O #00K8 in cu.ft@lb7.
> H #00 gpm
+( H 10 psi.
0olution? 4.F4E i.d.
,0
This is a ballpar) figure the 9eynold>s number must be found to ensure a more accurate
calculation. This formula is?
Re H #0.1 6Jp7 @ du 6Crane 4",7
0olution H B F00 000
Crane %",# shows that the friction factor will change from .011 to .01B. %fter plugging
the correct friction factor into the first e$uation then solving the e$uation once again
yields a result of 4.FCE inner diameter.
The correct pipe size in this case is a #E sch;0 which has an inner diameter at #.0;B
inches.

,1
F., Pump Inlet Pipe
Figure 9.2.1 (i"ing +iagram
,,
Ta,le 9.2.2 .o&&e& through Fitting&
P$#p %nlet P!pe & '!tt!n(s Losses
Component 1 Ft E2u)'3 lenth 4uant)ty
Entry 037" 20 1
E5)t 1 2 1
El6o* 7#089 30 14 1
: 0;h 40 ! 1
.otal E2u)'alent <)pe %ength$ 124=
'ere are the re$uired formulas to size the pipe as found in the Crane manual?
+( H 0.000,11 6f!pJN,7 @ dN# 6Crane 4",7
+( H # psi
/ H 0.01B
. H 1,;>
" H ;C.F;C
> H #00 gpm
0olution# ;.01FE i.d.
5nce again the pipe size will be #E sch;0 which has an inner diameter of #.0;BE.
,4
F.4 Superheated steam boiler outlet pipe
Figure 9.3.1 0u"erheated 0team Boiler Outlet (i"e
Ta,le 9.3.2 .o&&e& through Fitting&
Bo)ler &)0;harge to /team .ur6)ne <)pe

Component 1 Ft E2u)'3 lenth 4uant)ty

Entry 037" 32 1
E5)t 1 44 1
El6o* 7489 1! # 2
El6o* 7#089 30 20 2
": 0;h 40 ! 1

.otal E2u)'alent <)pe %ength$ 10
,;
I used the DSE curve on page 4",, of the Crane manual to get a ballpar) pipe size of CE
sch ;0 pipe. This pipe size 6CE sch ;07 will be used in the rest of the calculations.
9eynold>s P for 1F; 441 lbs @ hr of steam through CE sch ;0 pipe.
Re H 1.41 6=@du7
W H 1F; 441 lbs@hr
d H B.FC1E
u H 0.0,C 6Crane %",7
0olution H # ;CB ;0C
Friction /actor 6Crane %",#7 H 0.01;
+( H 0.000 004 410 Q6f!=N,Mbar7 @ 6dN#7R
F H 0.0,C
. H 1#0>
W H 1F; 441 lbs@hr
3,ar H 1.0401 6Crane %"1B7
d H B.FC1E
The pressure lost through the pipe and fittings is ? 1;.F psi.
,#
F.; (oiler blowdown pipes
The flow rate through the boiler blowdown pipes is only ,.# gallons per minute. Gsing
,E sch ;0 pipe will suffice for this application. This size of pipe is certainly oversized for
the flow rate because of this& the pressure loss through the pipe and fittings is negligible.
The larger than needed ,E pipe will assure clear flow of boiler blowdown.
10.0 Component Selection
10.1 (oiler Point !evel .etection
8our point level detection points are incorporated into the boiler ?
1. !%!! 3 !evel %larm !ow
,. !%! 3 !evel %larm !ow
4. !%' 3 !evel %larm 'igh
;. !%'' 3 !evel %larm 'igh 'igh
(oth the !%!! and !%! are measured with one level switch same goes for the !%'
and !%''. 5ne single switch has , probes inside of it which ma)es it ideal for this
application. The switch is made by Clar) 3 9eliance part P <%101 with soc)et
welded connections pictured in figure 10.1.1 meets the re$uirements needed to
assure safe operation for the high temperature and pressure conditions. See %ppendi2
C 3 D!evel Switch 5rdering InformationE for data sheet.
,1
Figure 12.1.1 Clar< Reliance E5121 .evel&itch !htt"#$$.clar<%
reliance.com$"roduct&$reliance$(roduct@.ine$.evelarm&.htm'
,B
Figure 12.1.2 .evel &itch dimen&ion&
!htt"#$$.clar<reliance.com$"roduct&$reliance$Catalog&$+3.1C."d/'
,C
Figure 12.1.3 .evel 0itch *n&tallation
10., 8low <lement Selection
5rifice plates are used for flow measurement e2clusively. Software available through
8o2boro was used to size the orifice plates and all of the ordering information as well as
sizing information can be found at the enof this report in appendi2 . 3 D5rifice Plate
Selection
,F
10.4 8low Transmitter Selection
FT1 0team Outlet Flo Tran&mitter
The 9osemount 11#1 differential pressure transmitter is used for steam outlet flow
measurement. It is connected to the process via flange taps as noted in the orifice sizing
section. The calibration settings are as follows?
Sero? 0E w.c.
Span? 1000E w.c.
The following order number is re$uired to assure the proper transmitter is ordered?
1111H( 4 0 12 B6 ;2
The model number table can be found in appendi2 . 3 DTransmitter 5rdering
InformationE at the end of this report.
FT2 ) FT3 Boiler Blodon Flo Tran&mitter&
9osemount 11#1 differential pressure transmitters are used for blowdown flow
measurement. They are connected to the process via flange taps as noted in the orifice
sizing section. The calibration settings are as follows?
Sero? 0E w.c.
Span? 100E w.c.
The following order number is re$uired to assure the proper transmitter is ordered?
1111H( - 0 12 B6 ;2
The model number table can be found in appendi2 . 3 DTransmitter 5rdering
InformationE at the end of this report.
40
FT- Boiler Feedater Flo Tran&mitter
The 9osemount 11#1 differential pressure transmitter is used for boiler feed water flow
measurement. It is connected to the process via flange taps as noted in the orifice sizing
section. The calibration settings are as follows?
Sero? 0E w.c.
Span? 1#0E w.c.
The following order number is re$uired to assure the proper transmitter is ordered?
1111H( 1 0 12 B6 ;2
The model number table can be found in appendi2 . 3 DTransmitter 5rdering
InformationE at the end of this report.
10.; (oiler !evel Transmitter
FT1 Boiler Water .evel Tran&mitter
The 9osemount 11#1 differential pressure transmitter is used to measure the water level
in the boiler via a wet leg setup as pictured in figure 10.;.1
41
Figure 12.-.1 .evel Tran&mitter *n&tallation
4,
The calibration settings for this level transmitter are as follows?
Sero? B.C;CE w.c.
Span? 41.4F,E w.c.
=ith the specific gravity of the boiler water being .BC;C the calibrations above will
monitor the boiler level between 0E and 40E inches of fluid. The following order number
is re$uired to assure the proper transmitter is ordered?
1111H( - 0 12 B6 ;1
11.0 Conclusion
This report has been written to meet the re$uirements of the third year %utomation
Technology course. I learned a lot while researching the various components that I have
selected throughout the report. There is without a doubt a lot of information to ta)e into
account when sizing and putting into play a control strategy such as three element feed
water. Paying close attention to detail in a report li)e this would pay off if the pro/ect
was ever underta)en. =iring diagrams and programming need to be perfect in order to
have a successful installation.
44
Re/erence&
1. http?@@www.energy.rochester.edu@cogen@chpguide.htm
,. http?@@www.cogeneration.org@
4. http?@@www.cogen.org@.ownloadables@Pro/ects@<.GC5-<ATCogenT-uide.pdf
;. http?@@www.cogeneration.net@
#. http?@@www.hatch.ca@<nergy@<nergyTConservation@<nergyT<fficiency@powerTcog
en.htm
1. http?@@appsci.$ueensu.ca@ilc@sustainability@energy@cogen.php
B. http?@@www.software.roc)well.com@
C. http?@@www.clar)"reliance.com@products@reliance@ProductT!ine@!evelarms.htm
F. http?@@www.emersonprocess.com@9osemount@
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